The loading shoe is in the left hand of the photo. The discharge skirt is downstream of the strike-off bar. Both of these are furnished as complete weldments.

Each of these two walls can be installed separately inside of the support frame. All of the modules are assembled together at the plant prior to shipment to assure proper fit.

Overview

This system is designed with four main modules for each of the two walls: Loading Shoe and

Discharge Skirt.

Our Primary Belt Feeders can replace your apron/pan feeders

Installation

Feeders

The next two modules form the support framework for the loading shoe and the discharge skirts. They include the sidewall supports and the longitudinal strong backs for the assembled loading shoe and skirt. Included are the bolt-in knee braces to the floor structure above.

The back door to the loading shoe is a part of this frame. All of the subassemblies are bolted together. This requires little or no field fitting.

Primary Belt

The final element of this all-inclusive design is the feeder roller table which is designed to be installed in ten modular cassette trays.

The roller table is extended to the limits of the support bar that is located next to the head pulley. All of the cassette frames can be removed from the side for ease in roller maintenance and replacement.

The back door to the loading shoe is a part of

the frame

Total assembled weight of the structural elements is

approximately 13,000 lbs. per feeder system

Two modules: loading shoe & discharge skirt

ValleyRubber.Solutions 1.256.784.5231

Performance Guarantee

Operation without spillage and dust from the skirting interface to the belt

Reduced HP and torque rise on the drive system due to loading shoe efficiencies

Protection and extended lifecycle on the feeder belt by: o Uniform full support under the belt with the roller

table o No scoring or scuffing under the skirt liners o Reduced tension on the belt from the drive pulley o Reduced shearing forces on the vulcanized splice

Feeder performance with “hard, sharp & angular” fed material

Features that control

2” AR600 steel lifecycle was ~90+ days. Ceramic/rubber liner performance is 8 – 20 times longer. (An 800%-2,000% increase in wear life)

Maintenance intervals are now significantly less frequent Rear door liners are properly designed to affect a much improved seal on the tail of the loading shoe Large rear door will facilitate safer and easier entry into the feeder, negating bridging over the discharge chute

at the head pulley for access

No welding/fitting on this frame or other steel liners No cleanup from skirt spillage Belt lifecycle is excellent, typically 2-3 years Energy savings on the drive, due to reduced torque and belt breakout forces No field fitting/welding/cutting of holes and components Structure lifecycle is expected to be indefinite/perpetual

Deadbed Liner- This illustration is of the

left hand side discharge of the shoe near

the strike-off bar. These ceramic and

rubber liners have significant internal

structure to withstand the heavy shear

forces in this loading zone.

Cost and Maintenance Expenses

Strikeoff Bar Support, via Overhead Floor Beams

Typical as-designed support configuration is depicted as

lighter shaded structure. Notice the overhead 18” deep

beams. A more cost effective design are feeders rigidly

secured to the floor below. Thrust forces are significantly

minimized with our loading shoe design and any additional

structure in the frame of the feeder is minimal.

ValleyRubber.Solutions

Discharge Wall Liners

Feeder

Loading Shoe Performance and Concept

The liners on the wall, (under the loading shoe Deadbed Ceramic Bars), have been in operation for 114 weeks as

of the date of this photo. Previously 2” AR600 operated for 12-14 weeks. The ceramic is lasting ten to twelve

times longer. As is usually the case, different zones in the feeder have different wear rates depending upon

location.

Model of the discharge wall downstream of the

Loading Shoe Discharge wall in a 60” feeder

Design

Existing loading shoe in a 60” Feeder taken at 50 weeks Model of a 72” feeder

ValleyRubber.Solutions

Footprint

Strikeoff Zone

Geometry Loading Shoe

Belt Travel

Strikeoff

(Above) 60” feeder during a 2008 maintenance

outage. Notice the straight walls that allow rock

to be loaded down hard onto the belt. Liner

lifecycle in this area is about 90 days.

Zone

ValleyRubber.Solutions

One of the key features of the Feeder System is the

modulating of forces within the feeder drawdown

compartment into the loading shoe. Specific to this

is the proper placement and geometric design of the

liners in the flow-zone surrounding the strikeoff bar.

This is critical if liner performance and belt life are to

be maximized. The optimum configuration allows for

material to move with the belt and not be pulled

and/or sheared by the belt.

Our engineering team and support staff is larger and more capable than ever and you now have a direct association with the manufacturer of the components within the solution. Combining the solid manufacturing capabilities of Valley Rubber with the proven Rockland Engineered brand provides you with a start-to-finish partner for projects that include field reconnaissance, engineering and manufacturing. Never a Project to Fail!

(Below) Top view of the double-tapered Loading Shoe. This is a significant reason for the reduction in shear forces in the

drawdown and transition zone within the feeder.

Comparison Cost Effectiveness

vs.

Rubber & Ceramic

Pictured Above; 114 Weeks and still running… Cost/ft2 ~= $482.00

Cost/week = $482.00/114 = $4.22/week

Cost effective basis: Steel @ $32.00/week Ceramic @ $4.22/week

32/4.22 = 7.5 Or….Ceramic is 7.5 times more cost effective.

In the location pictured,

the custom designed

Rubber/Ceramic liners are

over 7 times more cost

effective than the previous

steel liners. This does not

take into account labor or

hardware replacements for

the steel liners, such as

countersink bolts.

ValleyRubber.Solutions

AR600 Steel (2” thick)

Steel

Lifecycle; approximately 90 Days Cost/ft2 ~= $450.00

Cost/week = $450.00/14 = $32.00/week

Rubber and Ceramic (2” thick)